Alloy



i?atented .iuiy 4,, 393

ETEQ STATE No Drawing.

Original application August 26,

1936, Serial No. 98,075. Divided and this application November 13, 1937, Serial No. 174,483

1 Claim.

This invention is a divisional of my application Serial No. 98,075, filed August 26, 1936. It relates to an improved method of alloying lead and copper and lead, tin and copper, and to the product obtained from the use of this method. Heretofore in producing leaded bronze which is an alloy including lead and copper, it has been impossible to maintain a high lead content because on re-melting and re-casting the leaded bronze separation would take place.

The objects of this invention are:

First, to produce a new and improved method of alloying lead and copper so that they will not separate out on re-melting.

Second, to produce such a method in which a very high lead content may be used.

Third, to provide such a method in which a small quantity of another alloy is added to the lead and copper or lead, copper and tin during the course of the production of the leaded bronze which alloy greatly assists in the combining of the lead and copper and produces a highly satisfactory leaded bronze.

Fourth, to provide a new and improved leaded bronze.

Fifth, to provide such a new and improved leaded bronze containing in addition to the copper and lead an alloy which serves to prevent separation of the lead and copper during remelting and re-casting.

In carrying out my invention, I proceed with the following steps or stages:

First stage: Melt together 65.188% of copper and 31.426% of nickel. This percentage is the percent of the final alloy which is to be added to the copper and lead or copper, lead and tin.

If a standard alloy, 50% copper and 50% nickel,

added to the term-manganese to give the desired proportion. This may be accomplished by adding the necessary amount of manganese to the ferro-manganese to make the percentage called for.

Third stage: When the copper, nickel, manganese and iron are all thoroughly melted and well mixed and added together, add .442% phosphorus. If phosphor-copper is used the percentage of copper in the phosphor-copper must be taken into consideration in determining the proportions of copper so that the proportion of copper to phosphorus will be maintained in the final product.

Fourth stage: To the entire mixture I add .491% of a special aluminum alloy which is described in my copending application Ser. No. 98,076, filed Aug. 26, 1936. This alloy is made up of aluminum 88.23%, copper 5.31%, tin 2.65%, nickel .88%, magnesium .88%, manganese 1.66%, and silver .39%. Thoroughly stir and mix the aluminum alloy into the metal and bring the temperature of the combined mass to a minimum of 2500 F.

The product of these four stages is cast into pigs and results in an alloyto be added to lead and copper to assist the alloying of those mate-= rials.

I have found that the percentages above given can be varied somewhat. Nickel may vary from 26% to 31.426%. Manganese can vary from .491% to 2%. Iron may vary from .91% to 1%. Phosphorus may vary from .442% to 5% and the amount of aluminum alloy may run not to exceed 1% of the total, and the copper will be in sufficient quantity to complete the total of the composition. This alloy is described and claimed in my copending application Ser. No. 98,075 of which this application is a division. The alloy thus formed comprises nickel 26.0043% 31.514%, manganese .4992% to 2.1066%, iron .4910% to 1%, phosphorus .442% to 5%, aluminum .4332% to .8823%, tin .0130% to 0.265%, magnesium .0043% to .0088%, silver .0019% to .0039% and copper to make up 100% of the alloy;

In using this alloy in making leaded bronze, I add from 3% to 10% of the alloy to a given amount of copper. The percentage of the alloy is figured on the percentage of the finished leaded bronze and lead is added after the copper and the alloy have been reduced to the molten state. The quantity of lead may vary from 10% to 60% of the total content of the leaded bronze. By using my alloy the lead will be thoroughly suspended in the copper and the copper and lead will be perfectly amalgamated and will Le free from segregation and other imperfections usually found in leaded bronzes where the lead in large proportions is combined with copper or with copper and tin, as in high lead or anti-frictional bronzes for bearing metals, brake blocks for automobiles or kindred lines of industry, bushings, castings with metal of high lead content for industrial purposes such as tubes, linings, shingles and rods.

An alloy made up in accordance with the above method comprises lead 10% to nickel .780% to 3.1514%, manganese .0149% to .201'l%, iron .0147 to .1%, phosphorus .0112% to .5%, aluminum .0129% to .0882%, tin .0039% to .0027%, magnesium .0001% to .0009%, silver .00005% to .0004%, and copper to make up of the alloy. I

In using my alloy for combining copper and lead or copper, lead and tin, the bronze can be re-melted and re-cast several times.

I have found an alloy made up of 81% copper,

13% lead and 2% tin with 4% of my alloy added will produce a leaded bronze which compares very desired amount of copper for the formula of the finished leaded bronze. The copper is melted with my alloy in an amount of from 3% to 10% of the finished lead bronze. The copper and the alloy are subjected to a temperature of not less than 2500 F. until the copper and the alloy are completely melted. At this stage the lead is added or lead and tin are added if it is desired to add tin. 'The ingredients are then incorporated by agitation, thus forming a perfect leaded bronze of from 10% to 60% lead content. If it is desired to add tin this may be done as indicated.

I have re-melted and re-cast melted bronze in this manner as many as seven times without any HENRY L. WHITMAN. g5 

